10.1 Parts of the clutch pedal assembly
1 Engine compartment bulkhead with bracket support 3
2 Self-adhesive seal between bracket and bulkhead, replaceable, glued to the bracket
3 Bearing bracket for clutch pedal support
4 Bolt
5 Eccentric spring
6 Bush-bearing
7 Pedal axis
8 Clutch pedal
9 Support
10 Seal between cylinder 11 and bracket 3, to be replaced
11 Clutch master cylinder
12 Sensor "G476" clutch pedal positions
13 Clutch line retainer
14 Plastic tube or rubber hose
15 Self-locking nuts, 3 pcs., 25 Nm, to be replaced
16 Nut, 25 Nm, to be replaced
17 Clutch pedal stop
Sensor "G476" clutch pedal
2. Remove the air cleaner (see chapter 4) and battery with its holder (see chapter 5).
3. If a line is connected directly below the master cylinder (1 in illustration 5.8) hydraulic clutch (plastic or tube/hose), it should be removed. To do this, remove the plastic hose (3) off the master cylinder and plug it (but do not pinch, because. this will damage the hose), then pull out the lock with a screwdriver (2) to the stop and disconnect the line (1).
4. Disconnect the connector (4 in illustration 5.8) sensor "G476" and unhook it (arrow) from the master cylinder.
5. Installation is carried out in the reverse order. If the lower tube was disconnected, make sure that it is securely fixed when connecting.
Clutch pedal bracket
6. Remove the sensor "G476" (see subsection above), without disconnecting the wiring from it.
7. Line the floor covering in the driver's footwell with a cloth to collect brake fluid.
8. Remove the driver's glove box and lower plastic steering column trim (see chapter 11).
9. Remove the air duct in the driver's footwell.
10. If available, remove the knee airbag strut.
11. Loosen the master cylinder rod support using T10005 pliers (see resist. illustration).
10.11 Releasing the master cylinder rod holder
12. Release the lock tab (B on resist. illustrations) and pull the master cylinder out of the bracket in the direction of the arrows (1 and 2).
10.12 Separation of the master cylinder from the clutch pedal
13. Give nuts (2 to resist. illustrations) and remove the bracket (1).
10.13 Fixing the bracket
14. Installation is carried out in the reverse order. Use new gaskets and bracket mounting nuts; tighten them with a force of 20 Nm.
Eccentric spring
15. Move the driver's seat back and raise the steering column.
16. Follow the steps described in paragraphs 8-10.
17. Give the nut (2 to resist. illustrations) and pull out the bolt (5), to release the clutch pedal (1) from bracket (3).
10.17 Removing the spring
Note: The pedal remains hanging on the rod of the working cylinder. Slightly tilt the pedal down and remove the eccentric spring (4) from the bracket.
18. Insert eccentric spring (2 to resist. illustrations) into the bracket from above, holding its end in the installation position with tool T10178. Enter the axle into the spring, lightly press the clutch pedal (1), fully insert the axle and tighten the new self-locking nut to 25 Nm.
10.18 Installing the spring
Master cylinder
19. Remove the pedal bracket (see relevant subsection above).
20. Loosen the master cylinder rod support using T10005 pliers (see illustration 10.11).
21. Insert spacer (And in illustration 10.12) 40 mm between the pedal and stopper and press the pedal into the spacer. Release the locking tab (IN) and pull the master cylinder out of the bracket in the direction of the arrows (1 and 2).
22. Fully retract the pedal, connect the support (2 to resist. illustrations) to stock (1) master cylinder.
10.22 Installing the support on the stem
23. Insert spacer (And on the opposite illustrations) 40 mm between the pedal and stopper and press the pedal into the spacer. Hook the master cylinder into the bracket in the direction of the arrows (1 and 2).
10.23 Fixing the cylinder in the bracket
24. Press on the stem (1 per resist. illustrations) master cylinder in the direction of the arrow to support (2) fixed in the clutch pedal with a distinct sound.
10.24 Fixing the cylinder in the pedal
25. Install the pedal bracket.
Clutch pedal
26. Remove the eccentric spring (see paragraphs 16-19).
27. Loosen the master cylinder rod holder using T10005 pliers (see illustration 10.11) and remove the clutch pedal.
28. Installation is carried out in the reverse order. The process of connecting the pedal to the master cylinder rod is described in the subsection above.
Executive cylinder
29. Remove manual transmission (see Section 5).
30. Remove the retaining ring with a screwdriver (2 to resist. illustrations) and disconnect the bleeder housing (4) from the slave cylinder (1).
10.30 Removing the bleeder housing
31. Remove the bolts (see resist. illustration) and remove the slave cylinder with release bearing.
10.31 Bolts of fastening of the executive cylinder
32. Installation is carried out in the reverse order. Tighten the slave cylinder fastener evenly, in small increments. After installation, bleed the clutch hydraulic (see Section 9 of Chapter 1).